Photovoltaic Modular System

ABSTRACT

A photovoltaic modular system is disclosed. One or more photovoltaic (PV) modules are connected together with embedded parallel wiring that facilitates the sharing of power from a plurality of PV modules to power one or more electrical devices. Control electronics within each individual PV module allows the isolation of PV modules that are shaded or otherwise not productive. No external connecting wiring, or devices are required to make the system functional. All wiring, connectors and electronics are integral and embedded within each individual PV module. The PV modules have adhesive on the back to allow them to be installed without additional mounting hardware. All PV module system components are completely encapsulated together in one modular component.

BACKGROUND Field of the Invention

This invention relates to modular photovoltaic systems.

Background of the Invention

Solar power systems are typically mounted in a location facing the sunin order to maximize the exposure to solar energy. However, there can beobstructions to the direct sunlight needed to power the solar panels.Clouds, trees, and architectural features or building elements can causeshading. Even partial shading of the solar panel can dramatically reducethe power output since the electron flow inside the panel is in series.Shading of only one section or portion of the solar panel will block theflow for the entire panel or group of panels.

Traditional solar power systems normally include multiple solar panelsthat are connected to each other by either parallel or series wiring (ora combination of both).

Prior to the introduction of microinverters, most if not all solar powersystems were wired in series, having several “strings” of panels (agroup of many panels, circuited in series), with each string feedinginto a large power inverter that converted the DC power to AC power. Themain disadvantage of this design is the fact that if there is shading oneven one single panel within the string, it affects the current flow ofthat entire string (because they are wired in series), and reduces thetotal string power output to the lowest electrical current flowrestriction created by the shading of that one panel.

By wiring the system in a parallel configuration, this problem can besolved. The parallel wired systems typically invert the DC power to ACat each individual solar panel via a microinverter. This parallel wiredmicroinverter configuration allows each individual solar panel tooperate independently, and contribute its portion of power production tothe overall power of the combined system without restricting the currentflow. If there is shading on one single panel, the lower powerproduction of that panel does not restrict the total power production ofthe parallel string.

Many approaches to making solar power systems “modular” or easilyexpandable have been proposed in order to simplify the installation ofthe system. A large portion of these consist of unique mounting systemsthat attach to the roof, and connection techniques that allow multiplesolar modules or panels to be connected together. The attachment systemusually has some kind of rack or structure that first attaches to theroof or building structure, then the solar panels are mechanicallyattached to that support structure.

Some of the proposed modular systems incorporate parallel wiring alongwith microinverters that parallel with each other in order to interfacewith an AC system connected to the utility. However, they convert it toAC before performing the paralleling function. The parallel wiring isnot typically incorporated within each individual module. The parallelwiring that connects multiple solar modules is normally run separatefrom the module in a protected cabling, raceway or electrical busstructure. Also, the electronics that perform the paralleling functionare typically in a separate enclosure such as a microinverter, device orcomponent with requisite wires connecting it to the rest of the system.The interconnecting wiring is cut to length for the specific applicationor configuration.

The described solar power systems are typically for large solar panelsrather than smaller modules, and do not integrate the parallel wiringinto the individual modules. Smaller surface areas (for examplearchitectural features such as long narrow linear building fascias,columns or window frames) cannot accommodate these larger format solarpanels.

In summary, the key advantages posited for the photovoltaic modularsystem include a system that:

incorporates the parallel wiring into each individual module,

is in a smaller format that can fit on a variety of surfaces, even onesthat are narrow or small,

allows the modules to be directly connected together without the needfor additional interconnecting wiring,

has embedded wiring which allows the modules to be arranged in anyconfiguration, with pairs of module connectors on all four sides of themodule,

performs the paralleling function on the DC side prior to converting toAC,

incorporates the control electronics for the paralleling function insideeach module,

has a higher resolution for isolating sections of the system that areshaded by incorporating a group of smaller modules rather than one largemodule,

can adjust to fit both smaller surface areas and be extended to longerareas by adding more modules, and

can be directly attached to a smooth surface area without any otherseparate support structure.

SUMMARY

This invention has been developed in response to the present state ofthe art and, in particular, in response to the problems and needs in theart that have not yet been fully solved by currently available systemsand methods. Features and advantages of different embodiments of theinvention will become more fully apparent from the following descriptionand appended claims, or may be learned by practice of the invention asset forth hereinafter.

Consistent with the foregoing, a photovoltaic modular system isdisclosed which simplifies the installation of, improves the shadetolerance and power production of solar power systems.

By providing a segmented approach, multiple solar modules can beconnected in parallel in order to isolate individual solar modules thatare being shaded from the rest of the solar array. In this design(parallel rather than series), each solar module that receives enoughlight will contribute to the total power generated by the group. Shadedmodules will not interrupt the current generated by the productivepanels since they are electrically isolated when not producing.

Each solar module produces the same voltage, and the current theyproduce is additive to the current flowing through the system producedby all of the solar modules in parallel.

This design also allows the system to be expandable in the future, ifand when additional power is required. As additional solar modules areadded, the voltage remains the same and the current increases whichprovides the increased power capacity.

Another advantage of this system is the ability to adjust the overallsize of the system to fit the dimensions of the available surface area.With the segmented approach, the number of solar modules can be adjustedto fit the length required.

The aesthetics of having the solar on a long continuous surface is alsoimproved by allowing an entire linear surface to be covered with thesolar element rather than having visual breaks in the solar.

It will be readily understood that the components of the presentinvention, as generally described and illustrated in the Figures herein,may be arranged and designed in a wide variety of differentconfigurations. Thus, the following more detailed description of theembodiments of the invention is not intended to limit the scope of theinvention, as claimed, but is merely representative of certain examplesof presently contemplated embodiments in accordance with the invention.The presently described embodiments will be best understood by referenceto the claims and drawings.

Certain embodiments of the invented photovoltaic (PV) modular systeminclude: one or more photovoltaic (PV) modules, each PV moduleincluding: one or more photovoltaic cells; two or more moduleconnectors, wherein the module connectors physically couple the one ormore PV modules together; embedded parallel wiring running along oneside of a PV module directly adjacent to the one or more photovoltaiccells in the main body of the PV module continuously from the two ormore modular connectors on one end of the module to the two or moremodular connectors on the opposite end of the module, wherein theembedded parallel wiring serves as a pathway for a total combinedelectrical current of the one or more PV modules connected together.

The one or more PV modules further including control electronics thatisolate nonproductive PV modules from the one or more PV modulesconnected together in a system, allowing the combined current to passthrough without diminishing the overall power production of the one ormore PV modules; the control electronics modulate the power output ofthe one or more PV modules during periods of shading or lower powerproduction to provide a power contribution to the total power output ofthe one or more PV modules.

Each PV module is enclosed in an encapsulation material, enclosing theone or more photovoltaic cells, the two or more module connectors, theembedded parallel wiring, and the control electronics.

The PV modular system, wherein the one or more photovoltaic cells,embedded parallel wiring, control electronics, and modular connectorsfacilitate the interconnection of additional PV modules to increase thetotal system power output, the increase of total surface area covered,and the connection to and isolation from a group of interconnected oneor more PV modules.

The PV modular system, wherein the embedded parallel wiring is rated tohandle the combined electrical current of all of the interconnected oneor more PV modules. The PV modular system, wherein the one or more PVmodules are connecting and providing power to one or more electricalcomponents. The PV modular system, wherein the one or more electricalcomponents comprises a system for charging energy storage devices orcomponents.

The PV modular system, wherein the one or more PV modules are attachedto a window covering system, and the one or more PV modules areintegrated into window covering components at the time of manufacture ofa window covering system. The PV modules integrated into window coveringwherein the one or more PV modules are mounted to both the front andback of blind slats within the window covering system, and connect toand provide power to one or more electrical components via flexibleelectrical wiring that clips onto the support and control string betweenblind slats.

The PV modules integrated into window covering wherein the one or morePV modules are provided with a mounting system connecting to theheadrail of the window covering system that suspends the one or more PVmodules at a lower level where they will receive more exposure to thesun, and wherein the mounting system is adjustable, allowing the PVmodules to slide either up towards the headrail or down lower where theywill receive more exposure to the sun, locking in to the correctposition after being properly adjusted.

The PV modular system, wherein one or more PV modules each has a fullpower rating of the parallel wiring equal to or greater than a sum ofmaximum power production of a combined interconnected PV moduleassembly, electronic controls of the voltage and current of each PVmodule are incorporated into each PV module's internal circuiting, andthe embedded parallel wiring within the one or more PV modules providesan electrical pathway for both power and control functions.

The PV modular system, comprising peel and stick adhesive backing toallow the one or more PV modules to be adhered to a surface, and whereinthe one or more PV modules each comprises an extended encapsulationmaterial allowing multiple one or more PV modules to overlap and notcover or shade any active solar portion of adjacent one or more PVmodules.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the advantages of the invention will be readilyunderstood, a more particular description of the invention brieflydescribed above will be rendered by reference to specific embodimentsillustrated in the appended drawings. Understanding that these drawingsdepict only typical embodiments of the invention and are not thereforeto be considered limiting of its scope, the invention will be describedand explained with additional specificity and detail through use of theaccompanying drawings, in which:

FIG. 1A is a top view of three PV modules before they are connectedtogether.

FIG. 1B is a top view of three vertical PV modules that are connectedtogether.

FIG. 1C is a top view of three horizontal PV modules that are connectedtogether.

FIG. 2 is a cross section of a PV module showing the internalcomponents.

FIG. 3A is a top view of a PV module showing the internal components.

FIG. 3B is a top view of a PV module showing the overlap area forinterfacing with an adjacent PV module.

FIG. 4A is a top view of two PV modules prior to being connected.

FIG. 4B is a top view of two PV modules that are connected.

FIG. 4C is a side view of two PV modules prior to being connected.

FIG. 4D is a side view of two PV modules that are connected together.

FIG. 5 illustrates an example of how the PV modules can be mounted to awindow frame.

FIG. 6 shows a PV module mounted to the slat of a blind with wiringextending to the electrical components in the header of the blinds.

FIG. 7A illustrates an example of how PV modules are mounted tohorizontal blinds.

FIG. 7B illustrates an example of how PV modules are mounted to verticalblinds.

FIG. 8 illustrates an example of how the PV modules can be mounted toboth sides of a blind slat.

FIG. 9 is a perspective view of a PV module with the protective paperbeing peeled off of the adhesive backing.

FIG. 10A is a perspective view of a set of horizontal blinds with PVmodules shown overlapping each other on the header of the blinds.

FIG. 10B is a perspective view of a set of horizontal blinds with PVmodules on the header of the blinds.

FIG. 11A is a perspective view of a set of horizontal blinds showing theadjustable mounting system with PV modules mounted at the header of theblinds.

FIG. 11B is a perspective view of a set of horizontal blinds showing theadjustable mounting system with PV modules in a lower position below theheader.

FIG. 12A is a side view of the adjustable mounting system showing the PVmodule in the high position near the header.

FIG. 12B is a side view of the adjustable mounting system showing the PVmodule in the low position extended down below the header.

DETAILED DESCRIPTION OF THE DRAWINGS

It will be readily understood that the components of the presentinvention, as generally described and illustrated in the Figures herein,could be arranged and designed in a wide variety of differentconfigurations. Thus, the following more detailed description of theembodiments of the invention, as represented in the Figures, is notintended to limit the scope of the invention, as claimed, but is merelyrepresentative of certain examples of presently contemplated embodimentsin accordance with the invention. The presently described embodimentswill be best understood by reference to the drawings, wherein like partsare designated by like numerals throughout.

FIG. 1A is an illustration of one example of the PV modular systemcomprising three PV modules. The drawing 100 shows a top view of threePV modules before they are connected together. The module connectors 102on the top of the PV module are designed to connect to the moduleconnectors 104 on the bottom of an adjacent PV module. Each PV module106 is fully functional without any other modules connected to it.

FIG. 1B illustrates how three vertical PV modules are connected. PVmodule 106 is connected to two additional PV modules. The secondary PVmodule 108 overlaps the PV module 106 and the electrical connection atthe interface is made by the contact of top module connector 102 of PVmodule 106 with bottom module connector 104 of PV module 108. The thirdPV module 110 is connected in the same manner. These connections makethe embedded parallel wiring continuous across all three connected PVmodules, allowing the current to flow from all productive PV modules toprovide power the connected electrical components.

FIG. 1C illustrates how three horizontal PV modules are connected. A PVmodule 106 is connected to two additional PV modules. The secondary PVmodule 108 overlaps the PV module 106 and the electrical connection atthe interface is made by the contact of top module connector 102 of PVmodule 106 with bottom module connector 104 of PV module 108. The thirdPV module 110 is connected in the same manner. These connections makethe embedded parallel wiring continuous across all three connected PVmodules, allowing the current to flow from all productive PV modules toprovide power the connected electrical components.

FIG. 2 is a cross section of a PV module showing the internalcomponents. Photovoltaic cells 202 are arranged at the top of the PVmodule facing up and interconnected electrically. Module connectors 102are mounted on the top of the PV module. Module connectors 104 aremounted on the bottom of the PV module. Embedded parallel wiring 204connects to modular connectors 102 and module connectors 104, tophotovoltaic cells 202 and to control electronics 206. The encapsulationmaterial 208 completely encapsulates all of the components, integratingthem into one complete encapsulated assembly.

FIG. 3A is a top view of a PV module showing the internal components.Photovoltaic cells 202 are arranged at the top of the PV module facingup and interconnected electrically. Module connectors 102 are mounted onthe top of the PV module. Module connectors 104 are mounted on thebottom of the PV module. Embedded parallel wiring 204 connects tomodular connectors 102 and module connectors 104 and to theinterconnected photovoltaic cells 202 and to control electronics 206.

FIG. 3B is a top view of a PV module 106 showing the overlap area forinterfacing with an adjacent PV module. The active solar area 302 of thePV module consists of the photovoltaic cells. The outer perimeter 304 ofthe PV module can be overlapped by adjacent PV modules without coveringthe active solar area 302.

FIG. 4A is a top view of two PV modules prior to being connected. PVmodule 106 is designed to fit with adjacent PV module 108 and is shownwith positive 402 and negative 404 modular connectors. The embeddedparallel wiring 204 connects to the interconnected photovoltaic cells202 and extends the circuiting from PV module 106 to PV module 108 viathe control electronics 206.

FIG. 4B is a top view of PV modules that are connected. PV module 106 isoverlapping adjacent PV module 108 and is showing the positive 402 andnegative 404 modular connectors connected together. The embeddedparallel wiring 204 connects to the interconnected photovoltaic cells202 and extends the circuiting from PV module 106 to PV module 108 viathe control electronics 206.

FIG. 4C is a side view of two PV modules prior to being connected. PVmodule 106 is designed to fit with adjacent PV module 108 and is shownwith top modular connectors 102 and bottom modular connectors 104.

FIG. 4D is a side view of two PV modules that are connected together. PVmodule 106 is overlapping adjacent PV module 108 and is shown with topmodular connectors 102 and bottom modular connectors 104.

FIG. 5 illustrates an example of how the PV modules can be mounted to awindow frame. A continuous row of interconnected PV modules 502 is shownhorizontally above the window on the header frame. A continuous row ofinterconnected PV modules 504 is shown mounted vertically on the sidewindow frame.

FIG. 6 shows a continuous row of interconnected PV modules 608 mountedon the blind slat 624. Interconnecting electrical wiring 602 extendsfrom the PV modules 608 up to the electrical components 612 and energystorage devices 610, which are mounted inside the headrail 620. Theinterconnecting wiring 602 is flexible and is clipped onto the blindslat support string 604.

FIG. 7A illustrates a continuous row of interconnected PV modules 608mounted to the slats 624 of horizontal blinds 702.

FIG. 7B illustrates a continuous row of interconnected PV modules 608 isshown mounted to the slats 624 of vertical blinds 704.

FIG. 8 illustrates an example of how the PV modules can be mounted toboth sides of a blind slat. A continuous row of interconnected PVmodules 802 is mounted on the top of the blind slat 624. A continuousrow of interconnected PV modules 804 is mounted on the bottom of theblind slat 624.

FIG. 9 is a perspective view of a PV module with the protective paperbeing peeled off of the adhesive backing. PV module 106 is shown withadhesive material 902 on the back or bottom of the PV module. Theprotective paper backing material 904 is shown being peeled off to allowthe installation of the PV module onto a smooth surface.

FIG. 10A is a perspective view of a set of horizontal blinds with PVmodules shown overlapping each other on the header of the blinds. Acontinuous row of interconnected PV modules 608 are mounted on the blindheadrail 620. The overlapping of the two adjacent PV module 106 and PVmodule 108 is shown by the dashed lines 1002.

FIG. 10B is a perspective view of a set of horizontal blinds with PVmodules on the header of the blinds. A continuous row of interconnectedPV modules 608 are mounted on the blind headrail 620. The plurality ofPV modules visually appears as a continuous linear component across theentire length of the headrail.

FIG. 11A is a perspective view of a set of horizontal blinds showing theadjustable mounting system 1102 with a continuous row of interconnectedPV modules 608 mounted on the headrail 620 of the blinds.

FIG. 11B is a perspective view of a set of horizontal blinds showing theadjustable mounting system 1102 with a continuous row of interconnectedPV modules 608 in a lower position below the headrail 620.

FIG. 12A is a side view of the adjustable mounting system 1102 showing acontinuous row of interconnected PV modules 608 in the high positionnear the headrail 620. Locking mechanism 1202 retains the track in thishigh position.

FIG. 12B is a side view of the adjustable mounting system 1102 showing acontinuous row of interconnected PV modules 608 in the low positionbelow the headrail 620. Locking mechanism 1202 retains the track in thelow position.

1. A photovoltaic (PV) modular system comprising: one or morephotovoltaic (PV) modules producing a current, each PV module comprisingone or more photovoltaic cells; the PV module further comprising aplurality of contacts wherein the contacts couple the one or more PVmodules together; the PV module further comprising embedded parallelwiring connecting the contacts to the cells and to a controller; thecontroller comprising electronics that bypasses one or more non-currentproducing PV modules allowing the current to pass through to the one ormore PV modules; and the PV module further comprising an encapsulationmaterial enclosing the one or more photovoltaic cells, the plurality ofcontacts, the embedded parallel wiring, and the controller.
 2. Thecontacts of claim 1, wherein the contacts from a first PV module aremechanically connected to a second PV module.
 3. The contacts of claim1, wherein the contacts from a first PV module are connected to a secondPV module with a conductive adhesive.
 4. The PV modular system of claim1, wherein the one or more PV modules are connecting and providing powerto one or more electrical components.
 5. The PV modular system of claim4, wherein the one or more electrical components comprises a system forcharging energy storage devices or components.
 6. The PV modular systemof claim 1, wherein the one or more PV modules are attached to a windowcovering system.
 7. The PV modular system of claim 6, wherein the one ormore PV modules are integrated into window covering components at a timeof manufacture of a window covering system.
 8. The PV modular system ofclaim 6, wherein the one or more PV modules are mounted to both a frontand back side of blind slats within the window covering system.
 9. ThePV modular system of claim 6, wherein the connecting and providing powerto one or more electrical components comprises flexible electricalwiring that clips onto a support or control string between blind slats.10. The PV modular system of claim 6, wherein the one or more PV modulesare provided with a mounting system connecting to a headrail of a windowcovering system that suspends the one or more PV modules at a lowerlevel where they will receive more exposure to the sun.
 11. The mountingsystem of claim 10, wherein the mounting system is adjustable and theone or more PV modules slide either up towards a headrail or down lowerwhere they will receive more exposure to the sun, locking in to aspecific position after being properly adjusted.
 12. The PV modularsystem of claim 1, wherein one or more PV modules each has a full powerrating of parallel wiring equal to or greater than a sum of maximumpower production of a combined interconnected PV module assembly. 13.The PV modular system of claim 1, wherein electronic controls of thevoltage and current of each PV module are incorporated into each PVmodule's internal circuiting.
 14. The PV modular system of claim 1,wherein the embedded parallel wiring within the one or more PV modulesprovides an electrical pathway for both power and control functions. 15.The PV modular system of claim 1, comprising peel and stick adhesivebacking to allow the one or more PV modules to be adhered to a surface.16. The PV modular system of claim 1, wherein the one or more PV moduleseach comprises an extended encapsulation material allowing multiple oneor more PV modules to overlap and not cover or shade any active solarportion of adjacent one or more PV modules.
 17. The PV modular system ofclaim 1, wherein the embedded parallel wiring is rated to handle thecombined electrical current of all of the interconnected one or more PVmodules.
 18. A photovoltaic (PV) modular system comprising: one or morephotovoltaic (PV) modules producing a current, each PV module comprisingone or more photovoltaic cells; the PV module further comprising aplurality of contacts wherein the contacts couple the one or more PVmodules together; the PV module further comprising embedded parallelwiring connecting the contacts to the cells and to a controller; thecontroller comprising electronics that modulate the power output of theone or more PV modules during periods of shading or lower powerproduction to provide a power contribution to a total power output ofthe one or more PV modules; and the PV module further comprising anencapsulation material enclosing the one or more photovoltaic cells, theplurality of contacts, the embedded parallel wiring, and the controller.